Banner SureCross FlexPower DX80 Series User manual

Configurable temperature Node with thermocouple inputs and discrete I/O
Features
IP67 Base
2.4 GHz
IP20 Base
900 MHz
The SureCross™ wireless system is a radio frequency network with integrated I/O that
can operate in most environments while eliminating the need for wiring runs. Systems
are built around a Gateway, which acts as the wireless network master device, and one
or more Nodes.
• Wireless industrial I/O device with up to three configurable thermocouple inputs (de-
faults to J-type), two selectable discrete inputs, and two NMOS discrete outputs
• One thermistor input used for integrated cold junction compensation (CJC)
•FlexPower™ power options allows for +10 to 30V dc, solar, and battery power sour-
ces for low power applications.
• DIP switches for user configuration
• Frequency Hopping Spread Spectrum (FHSS) technology and Time Division Multi-
ple Access (TDMA) control architecture combine to ensure reliable data delivery
within the unlicensed Industrial, Scientific, and Medical (ISM) band
• Transceivers provide bidirectional communication between the Gateway and Node,
including fully acknowledged data transmission
• Lost RF links are detected and relevant outputs set to user-defined conditions
• The DX80...C models are certified for use in Class I, Division 2, Group A, B, C, D;
Zone 2 (Group IIC) Hazardous Locations when properly installed in accordance with
the National Electrical Code, the Canadian Electrical Code, LCIE/ATEX, or applica-
ble local codes/regulations (see Specifications)
For additional information, the most recent version of all documentation, and a complete list of accessories, refer to Banner Engineering's
website, www.bannerengineering.com/surecross.
Models
Model Frequency Environmental Rating I/O
DX80N9X2S2N2T 900 MHz ISM Band
IP67, NEMA 6 Inputs: Three thermocouople, two select-
able discrete, one thermistor input for
CJC
Outputs: Two NMOS sinking discrete
DX80N2X2S2N2T 2.4 GHz ISM Band
DX80N9X2S2N2TC 900 MHz ISM Band IP20, NEMA 1
Class I, Division 2, Group A, B, C, D Haz-
ardous Locations (see Specifications)
DX80N2X2S2N2TC 2.4 GHz ISM Band
Internal antenna models are also available. For more information, contact your local Banner Engineering Corp. representative.
WARNING: Not To Be Used for Personnel Protection
Never use this product as a sensing device for personnel protection. Doing so could lead to serious injury
or death. This product does NOT include the self-checking redundant circuitry necessary to allow its use in
personnel safety applications. A sensor failure or malfunction can cause either an energized or de-ener-
gized sensor output condition.
SureCross DX80 FlexPower Thermocouple Node
P/N 131297 rev. I 8/18/2011
0 131297 3

The SureCross DX80 Wireless Network
The SureCross DX80 wireless I/O network provides reliable monitoring without the burden of wiring or conduit installation. The SureCross
wireless network can operate independently or in conjunction with a host system, PLC, and/or PC software.
Each wireless network system consists of one Gateway and one or more Nodes. Devices ship with factory defined inputs and outputs
that may be all discrete, all analog, or a mix of discrete and analog I/O.
Gateway
Node
Node
FlexPower Node
and Battery Supply Module
The SureCross DX80 network is a deterministic system—the network identifies when the radio signal is lost and drives relevant outputs
to user-defined conditions. Once the radio signal is reacquired, the network returns to normal operation.
SureCross DX80 Gateways and Nodes
A Gateway acts as the master device within each radio network, initiates communication and reporting with the Nodes, and controls the
timing for the entire network.
The Gateway also holds the configuration for the network. Every wireless network must have one Gateway that schedules communica-
tion traffic and controls the I/O configuration for the network. A radio network contains only one Gateway, but can contain many Nodes.
Similar to how a gateway device on a wired network acts as a “portal” between networks, the SureCross Gateway acts as the portal
between the wireless network and the central control process.
A Node is a wireless network end-point device used to provide sensing capability in a remote area or factory. The Node collects data
from sensors and communicates the data back to the Gateway. Nodes are available in a wide variety of power or input/output options.
Each Node device can be connected to sensors or output devices and reports I/O status to the Gateway.
SureCross User Configuration Tool
The User Configuration Tool (UCT) offers an easy way to link I/O
points in your wireless network, view I/O register values graphically,
and set system communication parameters when a host system is
not part of the wireless network.
The UCT requires a special USB to RS-485 (model number BWA-
HW-006) converter cable to pass information between your computer
and the Gateway. Download the most recent revisions of the UCT
software from Banner Engineering's website: http://www.banneren-
gineering.com/wireless.
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Wiring Diagrams
5-pin Euro-Style Hookup (Nodes)
Wiring the 5-pin Euro-style connector depends on the model and power requirements of the device.
Wire No. Wire Color 10 to 30V dc Powered Nodes Battery Powered Nodes
1 Brown 10 to 30V dc
2 White
3 Blue dc common (GND) dc common (GND)
4 Black
5 Gray 3.6 to 5.5V dc
Connecting dc power to the communication pins will cause permanent damage. For FlexPower devices, do not apply more than 5.5V to
the gray wire.
DX80...C Wiring
Wiring power to the DX80...C models varies depending the power requirements of the model.
Terminal Label Gateway, DX85 * 10 to 30V dc Powered Nodes Battery Powered Nodes **
V+ 10 to 30V dc 10 to 30V dc
Tx RS485 / D1 / B / +
V- dc common (GND) dc common (GND) dc common (GND)
Rx RS485 / D0 / A / -
B+ 3.6 to 5.5V dc
* Connecting dc power to the communication pins will cause permanent damage.
** For FlexPower devices, do not apply more than 5.5V to the gray wire.
Terminal Block (IP67)
A4−
A4+
A2−
A2+
GND
PWR
DO2
DI2
A3−
A3+
A1−
A1+
GND
PWR
DO1
DI1
Ax+ and Ax-. Analog IN x. Analog inputs for devices requiring more than
one connection, such as thermocouples or RTDs. When there is no Ax-,
use Ax+ as an analog input.
DIx. Discrete IN x.
DOx. Discrete OUT x.
GND. Ground/dc common connection.
PWR. Power, 10 to 30V dc power connection.
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Terminal Block (IP20)
For the DX8x...C models, PWR in the wiring diagram refers to V+ on the wiring board and GND in the wiring diagram refers to V- on the
wiring board.
DI1
DI2
A1+
A1-
A2+
A2-
V+
V-
V-
DO1
DO2
A3+
A3-
A4+
A4-
TX
RX
B+
DIx. Discrete IN x.
DOx. Discrete OUT x.
GND. Ground/dc common connection.
PWR. Power, 10 to 30V dc power connection.
RX. RS485 / D0 / A - (used on Gateway only)
TX. RS485 / D1 / B / + (used on Gateway only)
V+. Power, 10 to 30V dc power connection.
V-. Ground/dc common connection.
Ax+ and Ax-. Analog IN x. Analog inputs for devices requir-
ing more than one connection, such as thermocouples or
RTDs. When there is no Ax-, use Ax+ as an analog input.
B+. 3.6 to 5.5V dc (for battery powered models only).
Wiring Diagrams for Discrete Inputs
Connecting dc power to the communication pins will cause permanent damage. For the DX8x...C models, PWR in the wiring diagram
refers to V+ on the wiring board and GND in the wiring diagram refers to V- on the wiring board.
Discrete Input Wiring (PNP) Discrete Input Wiring (NPN)
DIx
PWR or SPx
SureCross Device
DIx
GND
SureCross Device
Wiring Diagrams for Discrete Outputs
Connecting dc power to the communication pins will cause permanent damage. For the DX8x...C models, PWR in the wiring diagram
refers to V+ on the wiring board and GND in the wiring diagram refers to V- on the wiring board.
Discrete Output Wiring (NPN or NMOS)
DOx
PWR or SPx
SureCross Device
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Wiring Diagram for Thermocouple Inputs
Ax+
Ax−
TC
SureCross Device
+
−
Thermocouple: When wiring the thermocouple, x is the same number. For ex-
ample, a thermocouple is wired to A1+ and A1-.
Wiring Diagram for Thermistor Inputs
A4+
A4−
The thermistor at A4 is used for cold junction compensation. If the ther-
mistor is removed, all other analog temperature points will read “alarm.”
Thermistor model Number: BWA-THERMISTOR-001.
Supported Thermocouple Types
The Thermocouple Node supports up to three thermocouple inputs and defaults to the J-type thermocouple. The following thermocouples
are available by configuring the Node.
Thermocouple Range °F Range °C
Type B 212 to 3,272 °F 100 to 1,800 °C
Type C 32 to 4,208 °F 0 to 2,320 °C
Type E -58 to 1,832 °F -50 to 1,000 °C
Type J -292 to 1,382 °F -180 to 750 °C
Type K -292 to 2,282 °F -180 to 1,250 °C
Type L -328 to 1,652 °F -200 to 900 °C
Type N 32 to 2,192 °F 0 to 1,200 °C
Type R 32 to 2,912 °F 0 to 1,600 °C
Type S 32 to 2,642 °F 0 to 1,450 °C
Type T -238 to 752 °F -150 to 400 °C
Type U -148 to 1,112 °F -100 to 600 °C
Additional Information
For additional information, including installation and setup, weatherproofing, device menu maps, troubleshooting, and a list of accesso-
ries, refer to one of the following product manuals
• SureCross Quick Start Guide: Banner part number 128185
• SureCross Wireless I/O Network Manual: 132607
• Web Configurator Manual (used with "Pro" and DX83 models): 134421
SureCross DX80 FlexPower Thermocouple Node
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Modbus Register Table (High Resolution Mode)
I/O Modbus Holding Register I/O Type Units I/O Range Holding Register
Value
Terminal
Block La-
bels
Gateway Any Node Min.
Value
Max. Val-
ue
Min.
(Dec.)
Max.
(Dec.)
1 1 1 + (Node# × 16) Discrete IN 1 - 0 1 0 1 DI1
2 2 2 + (Node# × 16) Discrete IN 2 - 0 1 0 1 DI2
3 3 3 + (Node# × 16) Thermocouple IN 1 °F/°C -1638.3 +1638.4 0 65535 A1+/A1-
4 4 4 + (Node# × 16) Thermocouple IN 2 °F/°C -1638.3 +1638.4 0 65535 A2+/A2-
5 5 5 + (Node# × 16) Thermocouple IN 3 °F/°C -1638.3 +1638.4 0 65535 A3+/A3-
6 6 6 + (Node# × 16) Thermistor IN °F/°C -1638.3 +1638.4 0 65535 A4+/A4-
7 7 7 + (Node# × 16) Reserved
8 8 8 + (Node# × 16) Device Message
9 9 9 + (Node# × 16) Discrete OUT 1 - 0 1 0 1 DO1
10 10 10 + (Node# × 16) Discrete OUT 2 - 0 1 0 1 DO2
11 11 11 + (Node# × 16)
12 12 12 + (Node# × 16)
13 13 13 + (Node# × 16)
14 14 14 + (Node# × 16)
15 15 15 + (Node# × 16) Control Message
16 16 16 + (Node# × 16) Reserved
In high resolution mode, the temperature = (Modbus register value) ÷ 20. In low resolution mode, the temperature is (Modbus register
value) ÷ 2.
Temperature values are stored as signed values in the Modbus register. A 0 in the register is interpreted as 0°; and 65535 in the register
(0xFFFF) is interpreted as −1 ÷ 20 = −0.05° in high resolution mode and –1 ÷ 2 = –0.5° in low resolution mode.
Device Configuration
DIP Switch Changes
Before making any changes to the DIP switch positions, disconnect
the power. For devices with batteries integrated into the housing,
remove the battery for at least one minute.
DIP switch changes will not be recognized if power isn't cycled to
the device.
Accessing the DIP Switches
To access the DIP switches, follow these steps:
1. Unscrew the four screws that mount the cover to the bottom housing.
2. Remove the cover from the housing without damaging the ribbon cable or the pins the cable plugs into.
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3. Gently unplug the ribbon cable from the board mounted into the bottom housing. For Class I, Division 2 certified devices, skip this
step (the ribbon cable is glued).
4. Remove the black cover plate from the bottom of the device's cover.
The DIP switches are located behind the rotary dials. After making the neces-
sary changes to the DIP switches, place the black cover plate back into posi-
tion and gently push into place. Plug the ribbon cable in after verifying that
the blocked hole lines up with the missing pin. Mount the cover back onto the
housing.
DIP Switch Settings
Switches
Device Settings 1 2 3 4 5 6 7 8
Rotary switch address mode OFF*
Extended address mode ON
Temp °Fahrenheit OFF*
Temp °Celsius ON
High resolution (0.1 degree)** OFF*
Low resolution (1 degree) ON
Discrete sinking inputs OFF*
Discrete sourcing inputs ON
Thermocouple, J-Type OFF* OFF* OFF* OFF*
Thermocouple, B-Type OFF OFF OFF ON
Thermocouple, C-Type OFF OFF ON OFF
Thermocouple, D-Type OFF OFF ON ON
Thermocouple, E-Type OFF ON OFF OFF
Thermocouple, G-Type OFF ON OFF ON
Thermocouple, K-Type OFF ON ON OFF
Thermocouple, L-Type OFF ON ON ON
Thermocouple, M-Type ON OFF OFF OFF
Thermocouple, N-Type ON OFF OFF ON
Thermocouple, P-Type ON OFF ON OFF
Thermocouple, R-Type ON OFF ON ON
Thermocouple, S-Type ON ON OFF OFF
Thermocouple, T-Type ON ON OFF ON
Thermocouple, U-Type ON ON ON OFF
Host configured (overrides DIP switches) ON ON ON ON
* Default configuration
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** In high resolution mode, the temperature = (Modbus register value) ÷ 20. In low resolution mode, the temperature = (Modbus register
value) ÷ 2.
Address Mode
The SureCross wireless devices may use one of two types of addressing modes: rotary dial addressing or extended addressing. In
rotary dial address mode, the left rotary dial establishes the network ID and the right rotary dial sets the device ID. The wireless network
is restricted to a maximum of 16 devices.
Extended address mode uses a security code to "bind" Nodes to a specific Gateway. Bound Nodes can only send and receive informa-
tion from the Gateway to which they are bound. In extended address mode, wireless networks may contain up to 48 radio devices. For
more information on extended address mode, refer to the SureCross™ Wireless I/O Network product manual.
The device ships in rotary dial address mode by default, with the DIP switch in the OFF position. To use extended address mode, change
the DIP switch to the ON position.
Discrete Input Type
Select the discrete input type: sourcing (PNP) or sinking (NPN).
Host Configured
Selecting “Host Configured (override switches)” uses the factory’s default configuration for this device or allows a host system to set
parameters. If the host configured option is not selected, use the DIP switches to configure the device parameters.
Temperature Resolution
When set to high resolution, temperature values are stored to the nearest tenth (0.1) of a degree (default position). To measure tempera-
tures above 1600 degrees Fahrenheit or 1600 degrees Celsius, switch the DIP switch to the ON position and use low resolution mode. In
high resolution, the device cannot store values larger than 1600.
Temperature Units
Use the DIP switch to specify if the temperature is stored in degrees Fahrenheit or Celsius. The default position is OFF, setting the
temperature to Fahrenheit. For Celsius measurements, set this switch to the ON position.
Thermocouple Type
Use DIP switches 5, 6, 7, and 8 to select the thermocouple type. The default position is the OFF position for all switches, setting the
thermocouple to a J-type thermocouple.
Hibernation Mode and Sleep Mode
While in hibernation mode, the radio does not operate. All SureCross devices powered from an integrated battery ship from the factory in
hibernation mode to conserve the battery. To wake the device, press and hold button 1 for five seconds. To put any FlexPower or integra-
ted battery SureCross radio into hibernation mode, press and hold button 1 for five seconds. The radio is in hibernation mode when the
LEDs stop blinking, but in some models, the LCD remains on for an additional minute after the radio enters hibernational mode. After a
device has entered hibernation mode, you must wait one minute before waking it.
During normal operation, the SureCross radio devices enter sleep mode after 15 minutes of operation. The radio continues to function,
but the LCD goes blank. To wake the device, press any button.
Verify Communications
After powering up and binding the Gateway and its Nodes, verify all devices are communicating properly. Verify LED 1 is green. Until
communication is established with the Gateway, the Node’s LED 2 flashes red. When communication is established, the Node’s LED 1
flashes green.
A Node will not sample its inputs until it is communicating with the Gateway to which it is bound.
LED 1 LED 2 Gateway Status Node Status
(green on) Power ON
(green flashing)
RF Link OK
(red flashing) (red flashing)
Device Error Device Error
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LED 1 LED 2 Gateway Status Node Status
(yellow flashing)
Modbus Communication Active
(red flashing)
Modbus Communication Error No radio link (when flashing
once every three seconds)
For Gateway and Ethernet Bridge systems, active Modbus communication refers to the communication between the Gateway and the
Ethernet Bridge. For GatewayPro systems, the Modbus communication LEDs refer to the communication internal to the Gateway Pro.
For Gateway only systems, the Modbus communication LEDs refer to the communication between the Gateway and its host system (if
applicable).
When testing the Gateway and Node, verify all radios and antennas are at least two meters apart or the communications may fail.
Specifications
Radio
Range
900 MHz: Up to 4.8 kilometers (3 miles) *
2.4 GHz: Up to 3.2 kilometers (2 miles) *
Transmit Power
900 MHz: 21 dBm conducted
2.4 GHz: 18 dBm conducted, less than or equal to 20
dBm EIRP
900 MHz Compliance (150 mW Radios)
FCC ID TGUDX80 - This device complies with FCC
Part 15, Subpart C, 15.247
IC: 7044A-DX8009
2.4 GHz Compliance
FCC ID UE300DX80-2400 - This device complies with
FCC Part 15, Subpart C, 15.247
ETSI/EN: In accordance with EN 300 328: V1.7.1
(2006-05)
IC: 7044A-DX8024
Spread Spectrum Technology
FHSS (Frequency Hopping Spread Spectrum)
Antenna Connection
Ext. Reverse Polarity SMA, 50 Ohms
Max Tightening Torque: 0.45 N·m (4 in·lbf)
Link Timeout
Gateway: Configurable
Node: Defined by Gateway
* With the standard 2 dB antenna. High-gain antennas are availa-
ble, but the range depends on the environment and line of sight.
To determine the range of your wireless network, perform a Site
Survey.
General
Power*
Requirements: +10 to 30V dc or 3.6 to 5.5V dc low
power option (For European applications: +10 to 24V
dc, ± 10% or 3.6 to 5.5V dc low power option)
Consumption: Less than 1.4 W (60 mA) at 24V dc
Housing
Polycarbonate
Weight: 0.26 kg (0.57 lbs)
Mounting: #10 or M5 (M5 hardware included)
Max. Tightening Torque: 0.56 N·m (5 in·lbf)
Interface
Indicators: Two bi-color LEDs
Buttons: Two
Display: Six character LCD
Wiring Access
Four PG-7, One 1/2-inch NPT, One 5-pin Euro-style
male connector
* For European applications, power the DX80 from a Limited Pow-
er Source as defined in EN 60950-1.
Inputs
Discrete Inputs
Rating: 3 mA max current at 30V dc
Sample Rate: 1 second
Thermocouple Inputs
Sample Rate: 1 second
Report Rate: 16 seconds
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Report Rate: On change of state
Discrete Input ON Condition
PNP: Greater than 8V
NPN: Less than 0.7V
Discrete Input OFF Condition
PNP: Less than 5V
NPN: Greater than 2V or open
Accuracy: 0.1% of full scale reading + 0.8° C
Resolution: 0.1° C, 24-bit A/D converter
Thermistor (used for CJC)
Model: BWA-THERMISTOR-001
Accuracy: 0.4° C (10 to 50° C); Up to 0.8° C (−40 to
+85° C)
Resolution: 0.1° C, 24-bit A/D converter
Outputs
Discrete Outputs
Update Rate: 1 second
ON Condition: Less than 0.7V
OFF Condition: Open
Output State Following Timeout: OFF
Discrete Output Rating (NMOS)
Less than 10 mA max current at 30V dc
ON-State Saturation: Less than 0.7V at 20 mA
Environmental
Environmental
Rating for DX80 models:IEC IP67; NEMA 6; (See UL
section below for any applicable UL specifications)
Rating for DX80...C models: IEC IP20; NEMA 1 (In a
suitable enclosure: Class I, Division 2, Group A, B, C,
D; T4 −40 to 80° C)
Operating Temperature: −40 to +85° C (Electronics);
−20 to +80° C (LCD)
Operating Humidity: 95% max. relative (non-condens-
ing)
Radiated Immunity: 10 V/m, 80-2700 MHz
(EN61000-6-2)
Shock and Vibration
IEC 68-2-6 and IEC 68-2-7
Shock: 30g, 11 millisecond half sine wave, 18 shocks
Vibration: 0.5 mm p-p, 10 to 60 Hz
Refer to the SureCross™ DX80 Wireless I/O Network product manual, Banner p/n 132607, for installation and waterproofing instructions.
Operating the devices at the maximum operating conditions for extended periods can shorten the life of the device.
Certifications
DX8x...C (External Wiring Terminal Models)
CSA: Class I, Division 2, Groups A, B, C, D (Ex/A Ex nA II T4); Certificate: 1921239
LCIE/ATEX: Zone 2 (II 3G / Ex nA IIC); Certificate: LCIE 10 ATEX 1012 X
Included with Device
The following items ship with the DX80 radios.
Included with Device Model Qty Item
DX80 Access Hardware Kit * BWA-HW-002 4 Plastic threaded plugs, PG-7
4 Nylon gland fittings, PG-7
4 Hex nuts, PG-7
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